Unitized carton loads



Dec. 6, 1966 L. c. DICK ET AL 3,289,823

UNITIZED CARTON LOADS Filed May 5, 1964 :5 Sheets-Sheet 1 iii INVENTORSLLOYD C. D/CK,

AND FRANKCMcA/UTT GENE C. 53/518 Dec. 6, 1966 L c. DICK ET AL 3,289,828

UNITIZED CARTON LOADS Filed May 5, 1964 5 Sheets-Sheet 2 I NV FNTO RS LL 0 YD C 9/ CK,

M0 FRA/v/r'cMC A/Urr 65/1/15 0. 5/2/ 145 United States Patent 3,289,828UNITIZED CARTON LOADS Lloyd C. Dick, Frank C. McNutt, and Gene C. Bahls,Kalamazoo, Mich, assignors to KVP Sutherland Paper Company, Kalamazoo,Mich, a corporation of Delaware Filed May 5, 1964, Ser. No. 365,054 13Claims. (Cl. 206-65) This invention relates to packaging, and is moreparticularly concerned with a method for packaging a plurality of foldedand glued paperboard cartons into a unit load secured to a pallet base,and with the unit load provided thereby. As used herein, the terms boardand paperboar are synonymous.

Folded and glued cartons and similar items have commonly been shipped bypackaging them in small corrugated board containers. However, individualcorrugated containers are diflicult to handle in bulk, and are subjectto damage and deterioration if many such containers are piled to anygreat height. This is due largely to a tendency of the corrugatedcontainer to abosrb moisture during periods of high relative humidity.Excess moisture weakens the corrugated container, causing partialcollapse of loads and spoilage of cartons contained therein. Damage toglued cartons in corrugated containers is also caused by uneven stackingof such containers so that the corner strength in the corrugatedcontainer is not properly utilized, in which case pressure pointsdevelopat points on the corrugated container not designed to withstand thisstacking weight. This also results in damage to contents of thecontainer. Since the corrugated containers must be handled individuallyinto and out of a freight car or truck, considerable damage to thecontainers and contents often occurs during such transfers.

Recently the packaging industry has become interested in unitized loadsin which a plurality of small paperboard cartons are placed into onelarge container. In order to render the unit load sufficiently strong towithstand the rigors of transportation, it has been necessary to utilizeeavy corrugated board as the outer container for the unitized load. Thismethod of packaging has found favor with the industry, but is relativelyexpensive in practice because of the high cost of such large corrugatedcontainers. However, previously proposed alternative solutions to theproblem have suffered from one or more serious disadvantages such aslack of stability, rigidity, or resistance to moisture.

It is an object of the present invention to provide a novel method forpackaging materials such as folded and glued paperboard cartons inunitized loads. It is another object to provide such unitized loadswhich are highly resistant to moisture, impact, and vibration, and whichwill withstand the effects of heavy loads placed thereon, and which canmoreover be carried or conveyed by normal means and in normal mannerwithout danger of collapsing. It is a further object to provide unitizedloads of the type described which are affixed to a pallet base for easyhandling. It is an additional object to provide a palletized unit loadwhich is relatively inexpensive in practice. The accomplishment of theforegoing and additional objects will become more fully apparenthereinafter.

The invention in its preferred embodiment is illustrated by theaccompanying drawings in which:

FIG. 1 is a perspective view of a palletized unit load according to theinvention.

FIG. 2 is a perspective view of a palletized unit load in anotherembodiment of the invention.

FIG. 3 is a perspective view of a single tray containing a load ofknocked-down folding cartons.

FIG. 4 is a perspective view of the tray of FIG. 3 with one side panelpartially broken away.

FIG. 5 is a perspective view showing a complete layer of trays arrangedon a pallet base.

FIG. 6 is a perspective view of the layer of FIG. 5 after a cover hasbeen placed thereover.

FIG. 7 is a top diagrammatic view showing an overlapping arrangement oftwo layers.

FIG. 8 is a top diagrammatic view showing a different arrangement of twooverlapping layers; and

FIG. 9 is a fragmentary cross-sectional View through one end of a traywith cover in place.

According to the invention a palletized unit load is provided by placinga plurality of layers on a pallet and securing the layers to the palletby strap means. The pallet may have a slatted top and bottom structure,or may be of solid construction. Each layer comprises a plurality oftrays each containing a plurality of K.D. (knocked-down) folded andglued paperboard cartons vertically arranged. A plurality of corrugatedreinforcing pads are placed in each tray, at least one at each end ofthe tray, to increase the load supporting properties of the individualtray unit. A group of trays is placed in a layer on a pallet, such as anexpendable one made of Wood, and arranged in rectangular form,preferably in an arrangement whereby the shape of the layer correspondsto the shape of the pallet. A unitary cover formed of paperboard andhaving depending flanges is placed over the entire group of trays of thelayer. Additionally, an inverted unitary tray may be placed under thefirst layer to prevent lateral shifting. In a preferred embodiment boththe trays and the cover are formed of a paperboard material which hasbeen coated with a moisture-resistant plastic material such aspolyethylene. Addi tional layers are added in a similar manner, andstrap means utilized to secure the layers to the pallet. The resultingstructure is strong, rigid, impact-resistant, and has high compressivestrength.

Reference is now made to the accompanying drawings for a betterunderstanding of the invention, wherein all the parts are numbered andwherein the same numbers are used to refer to corresponding partsthroughout.

Referring to FIGS. 1 and 2, completely assembled palletized unit loadsare shown comprising a pallet l, which is commonly constructed of wood,and a plurality of trays 2 arranged in layers, each layer having a fulllayer unitary cover 3 covering the entire layer and serving to hold thetrays of each layer together as a unit. The cover 3 may be either ofcorrugated board or a cylinder type of paperboard. If an ordinarypaperboard cover is used on each individual layer, an additionalcorrugated full layer cover is usually placed over the top layer beforebanding. As shown in FIGS. 1 and 2, an inverted cover 3' may be placedunder the first layer of trays. A plurality of layers are assembled oneach pallet and secured thereto by means of straps 4 commonly made ofsteel or plastic such as Dymax strapping. Corrugated edge protectors 5are placed under the straps 4 at the edges of the top layer to preventdefacement or destruction of the cover when a substantial force isapplied by the straps 4. In FIG. 1 the trays in each layer are arrangedin two rows, one row comprising three trays in side-to-side abutment andthe other row comprising two trays in end-to-end abutment. The trays ofsucceeding layers are superimposed over the respective trays of thepreceding layer. In FIG. 2 the arrangement of the trays of eachsucceeding layer'is staggered so that each tray overlies an abutmentsurface between trays of the preceding layer. This arrangement serves tostabilize the unit load and prevent lateral shifting of the trays.

In FIG. 3 a single tray 2 is shown containing a plurality of verticallyarranged K.D. folding cartons 6. The tray may be of the self-locking endtype shown in FIGS.

3 and 9. In order to increase vertical compressive strength of the trayunit, a plurality of corrugated reinforcing pads '7 preferably havingvertical corrugation are placed in the tray. The pads should havesubstantially the same height as the trays. As shown the pads areU-shaped. However, any form wherein the ends of the pads aresubstantially at right angles to the main portion of the pads issuitable, as for example L-shaped or modified Z-shaped. The preferredarrangement is shown in FIGS. 3 and 4 comprising two pads positioned ineach half of the carton in facing relationship to form two endcompartments 8 and 9 defining an intermediate compartment 10therebetween. In the embodiment shown, the end compartments are designedto contain approximately 100 cartons and the intermediate compartment tocontain approxiately 50 cartons.

In FIG. a plurality of trays containing cartons and vertical supportsare shown positioned on a pallet 1. Various other arrangements may ofcourse be used. However, it is desirable that the overall dimensions ofeach layer conform substantially to the dimensions of the pallet.

In FIG. 6 the first layer has been completed by placing a cover 3thereover. The cover may be formed of paperboard or similar material,and has depending flanges 3a. Corner reinforcements 31) formed of amaterial such as tape or reinforced tape, e.g., gummed kraft, areapplied to secure the flanges 3a and to strengthen the structure.Subsequent layers are positioned in similar manner.

In a preferred embodiment, a corrugated board cover is placed over thetop layer to provide additional support and to withstand the stressapplied by the subsequent banding. Additionally, an inverted corrugatedcover 3 may be placed on the bottom of the first layer to providesupport against lateral displacement. The entire unit may then be handedwith steel or plastic straps to form a palletized unit load as shown inFIGS. 1 and 2.

The placement of the trays within each layer may take various forms.Moreover, the trays of succeeding layers may be placed in different orstaggered positions to provide overlapping in order to stabilize theload against lateral movement. Two arrangements are shown in FIGS. 1 and2 and have been described previously. In another arrangement, shown inFIG. 7, the trays in each layer may be arranged in a pinwheel pattern.An upper layer is shown by the solid lines having surfaces of abutment11. The trays of the layer immediately below are staggered with respectto the top layer and form surfaces of abutment shown by the broken lines12. FIG. 3 shows still another arrangement. Here one layer is composedof tWo trays having an end-to-end surface of abutment 13 and an adjacentrow of three trays having side-to-side surfaces of abutment 14 and 15.The layer below, shown by broken lines, comprises five trays inmirrored-image arrangement with respect to the top layer havingsideto-side surfaces of abutment 16 and 17, and an end-toend surface ofabutment 18. Succeeding layers alternate in similar manner. Thisarrangement has been found to increase resistance to lateraldisplacement materially. In a preferred embodiment of the invention,both the tray and the cover are formed of paperboard material which hasbeen coated with a plastic material highly impermeable to moisture, suchas polyethylene, polypropyl ene, silicone resin, wax, or the like. Thisexpediency enables the palletized unit loads to be stored over a longperiod of time and even under relatively humid conditions withoutdeterioration or loss of structural strength and rigidity. In thefragmentary view of FIG. 9, the cover 3 is shown having a coating 19applied to both surfaces thereof, while the tray 2 has a coating 20applied to both surfaces thereof. However, satisfactory results areobtained if a coating is present on only one surface of the cover and/ortray. As shown in FIG. 9, the tray is of the locking end type ofstructure.

The following examples are given by way of illustration only and are notto be construed as limiting.

Example 1 A unitary load was prepared and placed on a 46% inch by 44%inch pallet, utilizing six layers of six trays per layer, making a totalof 36 trays per pallet load, and containing 9,000 K.D. (knocked-down)folding paperboard cartons per pallet load. Each succeeding layer wasstacked with the individual trays superimposed directly overcorresponding trays of the preceding layer, as in FIG. 1. Each tray wasfilled with vertically positioned folded ice-cream cartons. Fourcorrugated U-shaped reinforcing pads having vertical corrugations wereinserted, one at each end of the tray, and, additionally, one spacedcartons inward from each end, as shown in FIGS. 3-5, to add compressivestrength and stability not only to the tray container, but also to theentire unit load.

An inverted cover was first placed on the pallet and the first layer oftrays inserted therein, in a pattern comprising two rows of three layerseach. Successive layers each comprising two rows of three layers eachwere stacked in the pattern shown in FIG. 1.

Each layer was stacked in a stacking pattern comprising two rows ofthree trays each, as shown in FIG. 1. A corrugated board full layercover Was placed over each layer. The entire pallet load of six layerswas secured with four plastic straps (#504 Signode Dyrnax straps)- twolength and two girth. The load was vibrated on a Gaynes vibrator, andthe test was conducted with one gate positioned on the vibrator. The endand side of the pallet load were blocked with two inch by four inchpieces secured to the vibrator floor to prevent the pallet load frommoving off the vibrator car during testing. The pallet load wassubjected to vibration for one hour at r.p.m. The load stood upsatisfactorily throughout the test. The load was then subjected to astatic load test by placing a 1600 pound stacking weight on the palletload for 20 hours. No damage to the cartons resulted. The load alsosuccessfully withstood an 11 mile per hour impact test. The load alsowithstood subsequent warehouse tests and truck shipments.

Example 2 A pallet load was prepared utilizing five trays per layer,with the trays arranged in a row of three trays and an adjacent row oftwo trays. Each tray was filled with KD folding ice-cream cartons.Corrugated U-shaped reinforcing pads were inserted at each end of thetray and also at 100 cartons in from each end. The two center pads Wereturned with the flange pointing toward the end of the trays. Instead ofa full layer corrugated cover, as in Example 1, a full layer covercomprised of a polyethylenecoated paperboard was utilized. Thepaperboard material was the same as that employed for the individualtray containers. Spot glue areas were used between the full layer coverand the bottom of the tray containers of the next layer placed thereoverto help lock the load in place. A corrugated full layer cover wasutilized in conjunction with the paperboard full layer cover on the toplayer to provide strength for the strapping and possible double tieringon the top layer. The entire pallet load of six layers Was secured withfour #504 Signode Dymax straps (two length and two girth). The load wasvibrated for one hour and subsequently impacted. Although, duringvibration, the load was not quite as stable as that described in Example1 utilizing corrugated full layer covers over each layer, the slightmovement of the load was not serious. After vibrating and impacting, theload was dismantled and examined and evidenced no damage to the foldingice cream cartons.

Example 3 A pallet load Was prepared utilizing four trays per layer in apinwheel arranged stacking pattern, as shown in FIG. 7. Three #504Signode Dymax straps (two length and one girth) were employed to securethe unit. The load succes fu ly passed the vibration and impact tests.

The method and palletized unit load of the present invention represent asignificant improvement in the art. The invention enables palletizedloads to be readily prepared which may be conveniently handled forshipment, and which successfully withstand vibration, impact andcrushing, to which forces such loads are normally subjected in transit.Moreover, because the use of an expensive complete corrugated outercontainer is avoided, a substantial reduction in material cost isachieved.

It is to be understood that the invention is not limited to the exactdetails of construction, operation, or exact materials or embodimentsshown and described, as obvious modifications and equivalents will beapparent to one skilled in the art, and the invention is therefore to belimited only by the scope of the appended claims.

We claim:

1. A palletized load comprising a pallet base and a plurality of layerssecured thereto by strap means, each of said layers comprising aplurality of paperboard trays arranged in a substantially rectangularpattern, each of said trays containing a plurality of knocked-downfolding paperboard cartons arranged in a vertical plane and a verticalreinforcing member formed of corrugated board and comprising a bodymember having at least a portion extending along the width dimension ofsaid tray and at least one end member disposed at right angles thereto,and a unitary paperboard cover having a peripheral depending flangedisposed over and encircling the trays of said entire layer.

2. A palletized load according to claim 1 wherein an inverted unitarycorrugated board cover is mounted on said pallet and the first layer oftrays is contained within said cover.

3. A palletized load according to claim 1 wherein the corrugations ofthe vertical reinforcing member are vertical.

4. A palletized load according to claim 1 wherein the bottom of eachtray is adhesively afiixed to the cover immediately below.

5. A palletized load according to claim 1 wherein the paperboard ofwhich said trays and said cover are formed is coated with a plasticmaterial.

6. A palletized load according to claim 5 wherein sail plastic materialis polyethylene.

7. A palletized load according to claim 1 wherein thr top layer has acover thereover comprised of corrugatec board.

8. A palletized load according to claim 1 wherein eacl layer has acorrugated board cover.

9. A palletized load according to claim 1 wherein the height of saidreinforcing member is substantially the same as that of said tray.

10. A palletized load according to claim 1 wherein each tray containstwo pairs of U-shaped reinforcing members, each pair being arranged infacing relationship and positioned at an end of said tray, whereby threecompartments are defined.

11. A palletized load according to claim 10 wherein trays of adjacentlayers are arranged in staggered relationship with respect to eachother.

12. A palletized load comprising a pallet base and a plurality of layerssecured thereto by strap means, each of said layers comprising aplurality of polyethylenecoated paperboard trays arranged in asubstantially rectangular pattern, each of said trays containing aplurality of knocked-down folding paperboard cartons vertically arrangedand a plurality of U-shaped vertical reinforcing members formed ofcorrugated board, and a polyethylenecoated unitary paperboard coverhaving a peripheral depending flange disposed over and encircling thetrays of said entire layer, the top layer being covered with anadditional corrugated board cover, said reinforcing members and trayshaving substantially the same height.

13. A palletized load according to claim 12, wherein trays of adjacentlayers are arranged in staggered relationship with respect to eachother.

LOUIS G. MANCENE, Primary Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3,289,828 December 6, 1966 Lloyd C. Dick et a1.

It is hereby certified that error appears in the above numbered petentrequiring correction and that the said Letters Patent should read ascorrected below.

In the heading to the printed specification, lines 4 to 6', for"assignors to KVP Sutherland Paper Company, Kalamazoo, Mich. acorporation of Delaware" read assignors, by mesne assignments, to BrownCompany, a corporation of Delaware column 3, line 48, for "FIGURE 3"read FIGURE 8 Signed and sealed this 19th day of September 1967.

(SEAL) Attest:

ERNEST W. SWIDER Attesting Officer EDWARD J. BRENNER Commissioner ofPatents

1. A PALLETIZED LOAD COMPRISING A PALLET BASE AND A PLURALITY OF LAYERS SECURED THERETO BY STRAP MEANS, EACH OF SAID LAYERS COMPRISING A PLURALITY OF PAPERBOARD TRAYS ARRANGED IN A SUBSTANTIALLY RECTANGULAR PATTERN, EACH OF SAID TRAYS CONTAINING A PLURALITY OF KNOCKED-DOWN FOLDING PAPERBOARD CARTONS ARRANGED IN A VERTICAL PLAND AND A VERTICAL REINFORCING MEMBER FORMED OF CORRUGATED BOARD AND COMPRISING A BODY MEMBER HAVING AT LEAST A PORTION EXTENDING ALONG THE WIDTH DIMENSION OF SAID TRAY AND AT LEAST ONE END DISPOSED AT RIGHT ANGLES THERETO, AND A UNITARY PAPERBOARD COVER HAVING A PERIPHERAL DEPENDING FLANGE DISPOSED OVER AND ENCIRCLING THE TRAYS OF SAID ENTIRE LAYER. 